Superfine fiber containing grey dope dyed component and the fabric made of the same

ABSTRACT

A gray dope dyed superfine fiber with neutral color hue and a fabric made thereof, wherein the mono-filament denier of the gray superfine fiber is of 0.03˜0.5 denier, and the fabric formed by the gray superfine fiber may be further deeply dyed to a desired color during dyeing and finishing stage; particularly, when the fabric after deep dye shall possess not only a desired touch of soft and exquisite but also a superior quality of color fastness to dry crocking over level 4, color fastness to wet crocking over level 3, color fastness to light over level 3, color change of color fastness to laundering over level 4, and color fastness to laundering with respect to PET stain resistance over level 4 and color fastness to laundering with respect to Nylon over level 3.

BACKGROUND OF THE PRESENT INVENTION

1. Field of the Present Invention

The invention relates to a gray dope dyed superfine fiber and the fabrics made thereof, particularly the fabric may be further deeply dyed to a desired colors by additional dyeing process during dyeing and finishing stage; and the fabric after deep dyeing shall possess not only better touch of soft and exquisite but also a superior quality of color fastness to crocking, color fastness to light and color fastness to laundering.

2. Description of Prior Act

Since the fabrics made of the superfine yarn with mono-filament denier of less than 0.5 denier have good touch of soft and exquisite, these kinds of fabric have been favorably received by the public when they appeared on the market, and have been widely used for clothing material and furniture decorating purpose.

However, owing to the high fineness of the fiber the surface area of the fiber relatively increases that causes the fiber unable to be dyed the deep color even the amount of dyestuff used in dyeing process reaches saturation condition, or the fiber may have been dyed to deep color but the color fastness is poor due to failure of penetration of dyestuff into the fiber structure. Therefore presently in order to obtain better color fastness, the conventional fabrics made of superfine fiber can only be dyed to the even light color.

For improving the problem of unable to be dyed to deep color or the problem of poor color fastness after the fabric is dyed to the deep color, and further for meeting the requirement of market, the fiber industry have devoted themselves in the related research work, meanwhile some patents of invention were also disclosed such as the International Publication No. WO 02/088444 A1 which provided a fabric made of a superfine yarn containing dope dyed component to improve the color fastness to laundering and color fastness to light of the fabric.

The invention disclosed in International Publication No. WO 02/088444 A1 had disclosed that the dope dyed component such as carbon black, pigment, dyestuff were employed and mixed together in proportion to obtain the desired color.

However, when the method is employed for production, the inherent drawbacks incurred by the method shall include the color matching and color mixing to the dope dyed component is extremely difficult, and if subsequently proceeding to change color of fabric is necessary it shall be extremely difficult to ensure that no any dope dyed component is left inside the pipe although pipe line cleaning work including to drain off the waste water and flush the pipe has completely finished.

Therefore, the above-mentioned method is unsuitable to mass production and unable to meet the requirement of the market of wide variety color change of fabric.

SUMMARY OF THE PRESENT INVENTION

For improving the above-mentioned drawbacks, the invention provides a fabric made of superfine yarn containing gray dope dyed component which may be further deeply dyed to different colors under lower dyestuff concentration through additional dyeing process during dyeing and finishing stage.

The fabric of the invention so obtained has good color fastness to crocking and color fastness to light, and has the advantage of reducing the loss caused by spending long period of time to drain off the waste water in case of color change.

Hence, the major purpose of the invention is to provide a superfine yarn having neutral color hue containing gray dope dyed component and the fabric made of the superfine yarn which mono-filament denier is within a range of 0.01˜0.5 denier.

The another purpose of the invention is to provide a fabric made of the gray superfine yarn of the invention may be further deeply dyed to the desired colors during dyeing and finishing stage through additional dyeing process, and particularly the fabric, after dyeing, shall possess not only a desired touch of soft and exquisite but also a superior color fastness to crocking, color fastness to light and color fastness to laundering.

DETAILED DESCRITION OF THE PREFERRED EMBODIMENTS

Since gray has a neutral color hue among the three primary colors of red, yellow and green, and does not lean towards any of the three primary colors, the fabric made of the said superfine yarn containing dope dyed component carries no any other color hue, it is much easier to do color match when the fabric is deeply dyed to the desired color through additional dyeing process during dyeing and finishing stage, and the gray dope dyed component can be formed by pigments or dyestuffs, but the dope dyed component formed by pigments provides better color fastness when applied on superfine yarn.

As for the percentage by weight of the gray dope dyed component added to the polymer of the present invention, no specific restriction is required but it is better to choose the range from 3˜15% by weight in general. When the amount of the gray dope dyed component added is less than 3% by weight it is apt to causing color deviation between spindles due to poor mixing effect with polymer. Whereas if the amount of dope dyed component added exceeds 15% by weight the spinning property and physical property shall be affected and become poor.

The invention also imposes no specific restriction on the form of and manner for adding the dope dyed component to polymer. Normally the method more popularly used for adding the dope dyed component to polymer is making the dope dyed component into the form of masterbatch, and is fed into melting machine together with polymer by employing dosing unit. The polymer mainly used in the invention is polyester. However, other ingredients such as Titanium dioxide, antibiotics, anti-ultraviolet ray agent or anti-flaming agent can also be added to the polymer to obtain other mechanical properties.

The superfine fiber containing dope dyed component of the invention has mono-filament denier of 0.01˜0.5 denier, and preferably of 0.03˜0.5 denier. When the mono-filament denier is greater than 0.5 denier, the fabric shall be deeply dyed to obtain deep color with real good color fastness without the needed of additional dyeing process by using dope dyed component to improve color fastness.

However, since the filament is in greater denier the fabric lacks the desired touch of soft and exquisite. Whereas when the mono-filament denier is less than 0.01 denier, the fabric will present the desired touch of soft and exquisite, but due to over-fine fiber more amount of dope dyed component is needed for improving the color value and color fastness, and the spinning and physical properties of the filament will become worse that cause the product unable to be accepted by customers.

However, there is no any specific restriction is required on the manufacturing of single filament of the superfine fiber containing gray dope dyed component of the invention having a mono-filament denier of 0.01˜0.5 denier. The filament may be made of single polyester by direct spinning method, or may be made of polyester and alkali easy soluble copolymerised polyester by bi-component spinning method to form split type or sea island type superfine compound yarn and than the alkali easy soluble copolymerised polyester is removed by employing the alkali-reduction treatment method to obtain superfine polyester fiber; normally when mono-filament denier is less than 0.25 denier the method of bi-component spinning followed by alkali-reduction treatment is often adopted while taking into consideration the productivity of spinning.

In addition, the form of the gray superfine yarn disclosed by the invention is not restricted by any specific requirement, but may be of the draw textured yarn, or full draw yarn, or air textured yarn; or the superfine yarn may be used to form differential shrinkage gray dope dyed superfine draw textured yarn or to form differential shrinkage gray superfine full draw yarn in combination with the high shrinkage yarn having a shrinkage rate of boiling water higher than 15%. Besides, if dope dyed component is added to the high shrinkage yarn having a shrinkage rate of boiling water higher than 15%, better effect is then obtained.

The manner for carrying out the additional dying process of the fabric made of the gray superfine yarn of the invention is not restricted by any specific requirement. The desired color hue and value of the fabric shall be obtained simply by adjusting the color value of the gray dope dyed superfine yarn or by adjusting the color chroma and value of dyestuff.

Following these procedures, the fabric made of the gray dope dyed yarn of the invention shall have the following properties: TABLE 1 Test item Test results Test method Color fastness Color change Over level 4 AATCC 61-2A-1989 to laundering PET Stain Over level 4 AATCC 61-2A-1989 resistance Nylon Stain Over level 3 AATCC 61-2A-1989 resistance Color fastness Color fastness to Over level 4 AATCC 8-1988 to crocking dry crocking Color fastness to Over level 3 AATCC 8-1988 wet crocking Color fastness to light Over level 3 AATCC 16E-1982 (20 hrs)

From Table 1 it shows that the fabric made of the gray dope dyed superfine yarn of the invention has a color change of color fastness to laundering over level 4, a color fastness to laundering with respect to PET stain resistance over level 4, and a color fastness to laundering with respect to Nylon stain resistance over level 3 when tested with method AATCC61-2A-1989; and has a color fastness to dry crocking over level 4, a color fastness to wet crocking over level 3 when tested with method AATCC8-1988; as well as a color fastness to light over level 3 when tested with method 16E -1982 (20 hrs).

PREFERRED EMBODIMENT OF THE INVENTION

The following practical examples and comparative example were tested with the following respective methods when carrying out the test for color fastness to laundering, color fastness to crocking and color fastness to light:

1. Color Fastness to Laundering:

The test method of AATCC61-2A-1989 was employed to carry out the color change of color fastness to laundering, the PET stain resistance and Nylon stain resistance. The greater test data shown in test results represents better color fastness to laundering.

2. Color Fastness to Crocking:

The test method of AATCC8-1988 was employed to carry out the color fastness to dry crocking and wet crocking. The greater test data shown in test results represents better color fastness to crocking.

3. Color Fastness to Light:

The test method of AATC16E-1982 (20 hrs) was employed to carry out color fastness to light. The greater test data obtained means better color fastness to light.

EXAMPLE 1

The mixture of 5% by weight of GYAT 0610 gray masterbatch and 95% by weight of PET polyester granules was used as island component, and the alkali easy soluble copolymerised polyester granules containing polyethylene glycol and sulfoisopathalic acid as sea component to produce gray dope dyed sea island type partially oriented yarn (POY) by means of bi-component spinning method. The proportion of sea to island was 30%:70%, filament winding speed is at 2500 m/s, denier of filament is 320 deniers, number of filament is 40, number of island per filament is 37. Then the sea island type POY and the high shrinkage spin draw yarn (SDY) having a shrinkage of boiling water of 40% and d/f=30 denier/12 filaments were combined to produce differential shrinkage gray dope dyed superfine draw textured yarn of 180 denier/52 filaments through texturing process.

Then the differential shrinkage gray dope dyed superfine draw textured yarn was knitted into cloth by knitting, and the fabric so obtained was then treated by alkali for weight reduction to dissolve and remove the sea component completely having only the island component and high shrinkage yarn remained. Now the mono-filament denier of the island component is 0.07 dpf.

The fabric, after weight reduction, was tested for color fastness to laundering, color fastness to crocking and color fastness to light directly without further additional dyeing process. The test results are as shown in Table 2.

EXAMPLE 2

The weight reduced fabric from example 1 is dyed to red by employing additional dyeing process with dyestuff of Dianix red XF 2% under 130° C.

Then the fabric was tested for color fastness to laundering, color fastness to crocking and color fastness to light, the test results are shown in Table 2.

EXAMPLE 3

Dyed the weight reduced fabric from example 1 to yellow by employing additional dyeing process with dyestuff Dianix Flavine XF 2% under 130° C.

Then the fabric was tested for color fastness to laundering, color fastness to crocking and color fastness to light. The test results are as shown in Table 2.

EXAMPLE 4

Dyed the weight reduced fabric from example 1 to blue by employing additional dyeing process with dyestuff Dianix navy XF 2% under 130° C.

Then the fabric was tested for color fastness to laundering, color fastness to crocking and color fastness to light. The test results are as shown in Table 2.

COMPARATIVE EXAMPLE 1

Use PET polyester granules containing 0.4 wt % TiO₂ as island component, and alkali easy soluble copolymerised polyester granules containing polyethylene glycol and sulfoisopathalic acid as sea component to produce sea island type POY by employing bi-component spinning method. The proportion of sea to island is 30%:70%, filament winding speed is at 2500 m/s, denier of filament is 320 deniers, number of filament is 40, number of island per filament is 37; Then the sea island type POY and the high shrinkage spin draw yarn having a shrinkage of boiling water of 40% were combined to produce differential shrinkage superfine draw textured yarn of 180 denier/52 filaments through texturing process.

Then the differential superfine draw textured yarn was knitted into cloth through knitting process, and the fabric so obtained was then treated by alkali for weigh reduction to dissolve and remove the sea component completely having only the island component and high shrinkage yarn remained. Now the mono-filament denier of island component is 0.07 dpf.

Then dyed the weight reduced fabric with dyestuff Dianix Black XF 6% under 130° C., and tested the fabric for color fastness to laundering, color fastness to crocking and color fastness to light by employing the same method as that employed in the example 1 to 4. The test results are as shown in Table 2. TABLE 2 Color fastness to laundering Stain Stain Color fastness to Color Color resistance resistance crocking fastness Dyestuff Color Change PET Nylon dry wet to light Without Dyestuff Gray level 5 level 5 level 5 level 5 level 5 level 4 (Example 1) Dianix red Red level 4 level 4 level 3-4 level 4 level 3-4 level 4 XF 2% (Example 2) Dianix Flavine Yellow level 4-5 level 4 level 4 level 4 level 4 level 4 XF 2% (Example 3) Dianix navy Blue level 4-5 level 4 level 4 level 4 level 4 level 4 XF 2% (Example 4) Dianix Black Black level 4 level 3-4 level 2-3 level 3-4 level 2-3 level 4 XF 6% (Comparative Example 1)

From Table 2 it shows that the fabric of example 1 containing gray dope dyed component made of superfine yarn through knitting has better color fastness to laundering, color fastness to crocking and color fastness to light.

Moreover, the fabric of example 2 through example 4 were dyed to deep colors of red, yellow and blue through additional dyeing process during dyeing and finishing stage, and since the fabric in example 2 to 4 are carried no other color hue, it is easier for matching the color so that the color fastness to laundering, color fastness to crocking and color fastness to light of example 2 to 4 are still as better as that shown in Table 2.

However the fabric of comparative example 1 was made of the superfine yarn containing no any gray dope dyed component through knitting which was dyed black during dyeing and finishing stage by employing additional dyeing process. The test results shown in Table 2 shows that the fabric had a relatively poor color fastness to laundering, color fastness to crocking and color fastness to light. 

1. A gray dope dyed superfine polyester fiber, comprising mono-filament denier of 0.01˜0.5 denier and containing gray dope dyed component 3˜15% by weight.
 2. The gray dope dyed superfine polyester fiber as defined in claim 1, wherein the mono-filament denier of the gray dope dyed superfine polyester fiber is of 0.03˜0.5 denier.
 3. The gray dope dyed superfine polyester fiber as defined in claim 1, wherein the mono-filanient denier of the gray dope dyed superfine polyester fiber is of 0.07 denier.
 4. A gray dope dyed superfine yarn, which is made of gray dope dyed superfine polyester fiber containing gray dope dyed component 3˜15% by weight and with mono-filament denier of 0.01˜0.5 denier.
 5. The gray dope dyed superfine yarn as defined in claim 4, comprising gray dope dyed draw textured yarn, gray dope dyed draw full draw yarn, or gray dope dyed draw air textured yarn.
 6. The gray dope dyed superfine yarn as defined in claim 4, which is combined with high shrinkage yarn having a shrinkage rate of boiling water higher than 15% to form differential shrinkage gray dope dyed superfine draw textured yarn.
 7. The gray dope dyed superfine yarn as defined in claim 4, which is combined with high shrinkage yarn having a shrinkage rate of boiling water higher than 15% to form differential shrinkage gray dope dyed superfine full draw yarn.
 8. The gray dope dyed superfine yarn as defined in claim 4, wherein the mono-filament denier of the gray dope dyed superfine polyester fiber is of 0.03˜0.5 denier.
 9. The gray dope dyed superfine yarn as defined in claim 8, comprising gray dope dyed draw textured yarn, gray dope dyed draw full draw yarn, or gray dope dyed draw air textured yarn.
 10. The gray dope dyed superfine yarn as defined in claim 8, which is combined with high shrinkage yarn having a shrinkage rate of boiling water higher than 15% to form differential shrinkage gray dope dyed superfine draw textured yarn.
 11. The gray dope dyed superfine yarn as defined in claim 8, which is combined with high shrinkage yarn having a shrinkage rate of boiling water higher than 15% to form differential shrinkage gray dope dyed superfine full draw yarn.
 12. The gray dope dyed superfine yarn as defined in claim 8, wherein the mono-filament denier of the gray dope dyed superfine polyester fiber is of 0.07 denier.
 13. The gray dope dyed superfine yarn as defined in claim 12, comprising gray dope dyed draw textured yarn, gray dope dyed draw full draw yarn, or gray dope dyed draw air textured yarn.
 14. The gray dope dyed superfine yarn as defined in claim 12, which is combined with high shrinkage yarn having a shrinkage rate of boiling water higher than 15% to form differential shrinkage gray dope dyed superfine draw textured yarn.
 15. The gray dope dyed superfine yarn as defined in claim 12, which is combined with high shrinkage yarn having a shrinkage rate of boiling water higher than 15% to form differential shrinkage gray dope dyed superfine full draw yarn.
 16. A fabric made of gray dope dyed superfine yearns by knitting, wherein the gray dope dyed superfine yearns contains gray dope dyed component 3˜15% by weight and with mono-filament denier of 0.07 denier, and the fabric has color change of color fastness to laundering over level 5, color fastness to laundering with respect to PET stain resistance over level 5, color fastness to laundering with respect to Nylon stain resistance over level 3; color fastness to dry crocking over level 5, color fastness to wet crocking over level 5 and color fastness to light over level
 4. 17. The fabric as defined in claim 16, wherein the fabric is obtained by dyeing to different colors through additional dyeing process during dyeing and finishing stage having color change of color fastness to laundering over level 4, color fastness to laundering with respect to PET stain resistance over level 4; color fastness to laundering with respect to Nylon stain resistance over level 3; color fastness to dry crocking over level 4, color fastness to wet crocking over level 3 and; color fastness to light over level
 3. 18. The fabric as defined in claim 16, wherein the gray dope dyed superfine yearns is combined with high shrinkage yarn having a shrinkage rate of boiling water higher than 15% to form as a differential shrinkage gray dope dyed superfine draw textured yarn.
 19. The fabric as defined in claim 18, wherein the fabric is obtained by dyeing to different colors through additional dyeing process during dyeing and finishing stage having color change of color fastness to laundering over level 4, color fastness to laundering with respect to PET stain resistance over level 4; color fastness to laundering with respect to Nylon stain resistance over level 3; color fastness to dry crocking over level 4, color fastness to wet crocking over level 3 and; color fastness to light over level
 3. 20. The fabric as defined in claim 16, wherein the gray dope dyed superfine yearns is combined with high shrinkage yarn having a shrinkage rate of boiling water higher than 15% to form as a differential shrinkage gray dope dyed superfine full draw yarn. 